Method for obtaining high-tenacity aramid yarn

ABSTRACT

The invention relates to a method for obtaining high-tenacity aramid yarn, wherein the yarn is made of a copolymer obtained from a mixture of monomers comprising DAPBI, an aromatic para-diamine, and an aromatic para-diacid, wherein the yarn is heated in at least two process steps, characterized in that in a first step the yarn is heated at a temperature of 200 to 360° C. at a tension of at least 0.2 cN/dtex, followed by a second step wherein the yarn is heated at a temperature of 370 to 500° C. at a tension of less than 1 cN/dtex. The invention further pertains to a multifilament aramid yarn spun from a sulfuric acid spin dope and having a tenacity of at least 2500 mN/tex.

This is a Divisional Application of Application No. 12/311,654 filed Apr. 8, 2009, which is a National Phase of PCT/EP2007/009901 filed Nov. 19, 2007, and which claims priority to European Application No. 060241049, filed Nov. 21, 2006. The disclosures of the prior applications are hereby incorporate by reference herein in their entireties.

The invention relates to a method for obtaining high-tenacity aramid yarn, wherein the yarn is a copolymer obtained from a mixture of monomers comprising DAPBI, an aromatic para-diamine, and an aromatic para-diacid, and wherein the yarn is heated in at least two process steps.

Methods of heat treating yarn of spun copolymer obtained from a mixture of monomers comprising DAPBI (5-(6)-amino-2-(p-aminophenyl)benzimidazole) and PPD (para-phenylene diamine) in a heating oven are known in the art. Typically, as-spun yarns are led through an oven at a temperature of about 450° C. The residence time of the yarn in the oven is controlled by the yarn speed and is usually set between 20 seconds and 5 minutes at controlled tensions between 0.2 and 1 cN/tex. Such method using a single heating step is for example known from CN 1473969. Methods of heat treating spun DAPBI-PPD copolymer yarn in two separate process steps are also known in the art. In the Russian patent RU 2017866 a two step heat treatment is disclosed. These polymers are subjected to a draw-out step up to 120 wt %, followed by wash and drying steps, followed by a heat treatment at 320 to 350° C., and a further drawing at 360 to 420° C. to 1-3 wt %. The first heat treatment step is carried out with the yarn on the bobbin by placing the bobbin in an oven for 30 minutes. In this method the yarn tension cannot be controlled and heat treatment times of the different layers of yarn on the bobbin will differ due to heat transport time through layers of yarn.

Thermal drawing was disclosed in Sugak et al., Fibre Chemistry, Vol. 31, No. 1, 1999. Heating was performed in a heating zone, and in addition the fibers were heated (at undisclosed temperature) when the samples were wound on spools. However, heating the yarns during the process of reeling-up will lead to an uncontrolled process which unfavorably contributes to the properties of the yarn. In RU 2045586 a similar process was disclosed wherein the filaments were reeled up, washed and dried, and as such heated at 350-370° C., and thereafter hot-drawn at 390-400° C. Yarns with high tenacity could be prepared, however, only with optimum amounts of DAPBI and Cl-PPD (2-chloro-p-phenylenediamine). Thus example 20 provides high tenacity yarn using 7.5 mole % DAPBI and 25 mole % Cl-PPD. RU 2045586 further teaches that any increase of DABPI content and/or any decrease of Cl-PPD content leads to decrease of tenacity. It was further found that tenacities of at least 2500 mN/tex could only be obtained in the presence of Cl-PPD (at least 20 mole %). It is stressed that using Cl-PPD and certainly higher amounts thereof, is less preferred because of the presence of chlorine since it may unfavorably affect the properties of the yarn when heat is used.

Again, the uncontrolled first heat treatment on the bobbin will unfavorably contribute to the final properties of yarn having high amounts of DABPI or low amounts of Cl-PPD.

It is therefore an objective of the present invention to provide a method that does not have the disadvantages of the known two-step heating processes, whereas the properties of the yarn having relatively higher amounts of DABPI and/or lower amounts of Cl-PPD are much better than as obtained by the conventional one-step method.

To this end the invention pertains to a method for obtaining high-tenacity aramid yarn, wherein the yarn is a copolymer obtained from a mixture of monomers comprising DAPBI, an aromatic para-diamine, and an aromatic para-diacid, wherein the running yarn is heated in at least two process steps, characterized in that in a first step the yarn is heated at a temperature of 200 to 360° C. at a tension of at least 0.2 cN/dtex, followed by a second step wherein the yarn is heated at a temperature of 370 to 500° C. at a tension of less than 1 cN/dtex.

The new method consists of two different heating steps in two heating zones, such as two sets of heating devices, such as ovens, or in one oven having a temperature gradient.

In the first step the yarn is pre-drawn to a tension that is as high as possible without disturbing the process. The temperature in this step is preferably kept at 240° C. to 330° C. The first step is preferably directly followed by a second drawing step at preferably 400° C. to 470° C. under low tension. Between the two steps there is preferably no winding and unwinding of the yarns. Preferably in both steps oxygen levels are kept below 0.5 wt %, preferably at about 0.25 wt %.

For optimum yarn properties it is important that no further process steps are performed between the two process steps. Thus for optimum results it is important that no winding and unwinding of the yarn occurs between the two process steps.

The yarn is led through the heating zones usually at a rate leading to a heat residence time of at least 5 seconds, preferably at least 10 seconds, most preferably at least 20 seconds in both heating zones.

The yarn tension in the heating devices (such as ovens) is controlled by the draw ratio in the ovens. In the second step the tension is kept as low as possible without disturbing the transport of the yarn. In practice this is usually about 15 cN for a bundle of approximately 130 dtex.

For obtaining the best results, i.e. the highest tenacities, the process steps are performed under conditions wherein the tension is kept as constant as possible. This can, for instance, be obtained by keeping the yarn speed fluctuations as small as possible.

It is further advantageous to use copolymers having a η_(rel) (relative viscosity) of at least 3.5. The relative viscosity can be measured by known methods, for instance as disclosed in EP1689805.

The monomers used for making the yarn of the invention comprise DAPBI, which stands for 5-(6)-amino-2-(p-aminophenyl)benzimidazole. The term “aromatic para-diacid” as used throughout this invention has the meaning aromatic para-diacid or derivative thereof. Usually the acid as such is not used as monomer for the polymerization reaction but an ester or halide thereof, more particularly the acid chloride is used.

The term “aromatic para-diamine” as used throughout this invention has the meaning aromatic para-diamine or derivative thereof. Examples are PPD, Cl-PPD, Me-PPD, MeO-PPD, and the like. Most preferably PPD and/or Cl-PPD are used. Although DAPBI is also an aromatic diamine, this compound is not included in the definition of “aromatic para-diamine”.

The DAPBI-PPD copolymer is obtained by co-polymerizing the aromatic diamine monomer 5-(6)-amino-2-(p-aminophenyl)benzimidazole and the aromatic para-diamine monomer p-phenylene diamine (PPD), and the aromatic para-diacid derivative terephthaloyl dichloride (TDC). Although not required, part or all of the above para-aromatic monomers can be replaced by other para-aromatic monomers, for instance part or all of PPD can be replaced by PPD analogues, such as 2-chloro-p-phenylenediamine (Cl-PPD), and TDC can be partly or fully replaced by Cl-TDC (2-chloroterephthaloyl dichloride).

Particularly useful yarns for use in this method are as-spun yarns. As-spun yarns are yarns that are spun but did not undergo a heating treatment at 200° C. or more. Particularly good results are also obtained for yarn (or as-spun yarn) obtained from a sulfuric acid spin dope. Yarns obtained from a sulfuric acid spin dope have a sulfur content of at least 0.1 wt %. It is advantageous to use sulfuric acid spin dopes, since by using such spin dopes much higher spinning speeds can be obtained than when

NMP- or DMAc-containing spin dopes are used. It is further preferred to have as low as possible hydrogen chloride contents in the yarn to prevent release of hydrogen chloride from the yarn. Hydrogen chloride contents lower than 0.5 wt % are preferred. Most preferred are yarns that are totally or virtually free from hydrogen chloride.

According to a preferred embodiment of the method the first process step is performed at 240 to 330° C. at a tension of at least 1 cN/dtex, preferably at least 3 cN/dtex. In principle, for obtaining the best results the tension is kept high during the first heat treatment. The highest possible tension is about 95 wt % of the breaking tension at the temperature applied. At higher tensions the yarn will break. To prevent any breakage it is preferred not to use tensions far above 90 wt % of the breaking tension at the temperature applied. Preferably the residence time used is mostly at least 20 seconds.

According to a preferred embodiment of the method the second process step is performed at 400 to 470° C. at a tension less than 0.2 cN/dtex. This tension is usually kept as low as possible. By using special equipment, such as a conveyor belt, tensions of as low as 0 cN/tex (i.e. no tension at all) can be achieved. The residence time is most preferably at least 20 seconds.

The highest increase of the tenacity in comparison with the conventional one-step method is obtained when the copolymer is made from a mixture of monomers wherein at least 12.5 mole %, preferably at least 17 mole % of the monomers is DAPBI. The copolymers can be prepared according to known methods, such as disclosed in U.S. Pat. No. 4,018,735 or WO 2005/054337.

The method according to this invention leads to aramid yarns having further improved tenacity. It was found that this method can lead to yarns having tenacity of approximately 200 mN/tex higher than conventionally produced yarns. It is therefore also an objective of the invention to provide a multifilament aramid yarn having a tenacity of at least 2500 mN/tex wherein the yarn is a copolymer obtained from a mixture of monomers comprising DAPBI, an aromatic para-diamine, and an aromatic para-diacid wherein at least 12.5 mole % of the monomers is DAPBI, less than 20 mole % is Cl-PPD, and wherein the yarn has a sulfur content of at least 0.1 wt %. Preferably the mixture comprises monomers wherein at least 17 mole % of the monomers is DAPBI. Such high-tenacity multifilament yarns spun from a sulfuric acid spin dope are not yet known. In another preferred embodiment the mixture only contains PPD as the aromatic para-diamine.

In an alternative embodiment according to the invention the multifilament aramid yarn has a tenacity of at least 2500 mN/tex wherein the yarn is made of a copolymer obtained from a mixture of monomers comprising DAPBI, an aromatic para-diacid, and an aromatic para-diamine which is exclusively PPD, wherein at least 12.5 mole % of the monomers is DAPBI, and wherein the yarn has a sulfur content of at least 0.1 wt %.

Preferably such multifilament aramid yarn has a tenacity of at least 2750, more preferably 2850 mN/tex. The multifilament yarn has at least 2 filaments. Most preferred multifilament yarns have at least 25 filaments. Monofilament yarns have been previously disclosed in U.S. Pat. No. 4,018,735 having tenacity 30 gpd (about 2650 mN/tex) for 10 mole % DAPBI (example 14) and 30.5 gpd (about 2690 mN/tex) for 25 mole % DAPBI (example 7). It should however, be born in mind that the tenacity in U.S. Pat. No. 4,018,735 was measured on the filaments, not on the yarn. These values therefore cannot directly be compared with the presently claimed values. According to the standard textbook Kevlar Aramid Fiber, by H. H. Yang ((John Wiley & Sons, 1993, pages 34-35) the tenacity of yarn is usually 80-85 wt % of the tenacity of a single filament. This factor should be kept in mind when comparing yarn properties with filament properties. Thus the filament values of U.S. Pat. No. 4,018,735 are in terms of the presently claimed yarn tenacities at the most about 2250 and 2290 mN/tex, respectively.

The invention is further illustrated by the following non-limitative examples.

General

The tenacity was measured according to the method described in ASTM D 885

The Na, S, Cl and Ca contents are determined by XRF as follows.

Sample Pretreatment

The sample was ground to a fine powder in a Herzog HMS 100 grinding mill with a tungsten carbide grinding vessel. The aramid powder was pressed to a 20 mm diameter tablet by a Fontijne TP 400 plate press at 175 kN pressure for 2 minutes.

XRF Measurement

This measurement was performed with a PW2400 Philips X-ray fluorescence spectrometer and aluminum sample holders for 20 mm tablets

The following instrumental settings were applied:

X-ray tube: Chromium anode

Detector: Flow Counter for Ca, Cl, Na, S.

Filter: None.

Collimator mask: 16 mm

Medium: Vacuum

The instrumental settings were as follows:

back- PHD- 2θ ground colli- setting angle offset T_(p) T_(b) mator UL/LL Line kV mA (°) (°) (s) (s) Crystal μm wt % Ca-Kα 60 50 113.200 +/−2.00 50 10 LiF200 150 80/20 Cl-Kα 60 50  92.810 +/−2.00 50 10 Ge 111 550 70/30 Na-Kα 50 60  28.180 +/−2.00 50 10 PX1 700 80/20 P-Kα 60 50 140.994 +/−1.60 50 10 Ge 111 550 80/20 S-Kα 60 50 110.680 +/−2.00 50 10 Ge 111 550 80/20

The principle of quantification is based on a linear relationship of Na—, S—, Cl—, and Ca—Kα-fluorescence intensities with known concentrations to give a calibration line, which line is used to determine unknown concentrations.

Example 1 (Comparative: One-Step Process)

A polymer obtained from a mixture of 25 mole % PPD and 25 mole % DABPI (and 50 mole % TDC) having η_(rel) 6.0 was dissolved in 99.8 wt % sulfuric acid, as described in WO 2006/045517. Zone temperatures in the twin screw extruder were between 90 and 75° C. The polymer concentration in the solution was 20 wt %, and the solution was spun through 50 spinning holes of 75 micron. The spinneret assembly was kept at 125° C. The flow was drawn in an airgap and coagulated in water of 2° C. After washing 0.5 wt % NaOH in water was used as neutralizing fluid, and in a second washing step the neutralizing fluid was washed off. The yarn was dried at 160° C. and reeled up at 147 m/min to obtain as-spun yarns.

This yarn has a linear density of 148 dtex, a tenacity of 1305 mN/tex and a modulus of 65 GPa.

This yarn was submitted to drawing in an oven at temperatures ranging from 400 to 475° C. under nitrogen. The residence time in the oven was 28 seconds in all cases. During this drawing various tensions were applied; ranging from 0.17 cN/dtex to 2.53 cN/dtex, as a result of drawing ratios between 1.01 and 1.03. The properties and the essential machine settings are given in Table 1.

TABLE 1 Tension in T Linear Elongation oven oven density Tenacity at break Modulus Toughness cN/dtex ° C. dtex mN/tex wt % Gpa J/g Untreated yarn 148 1305 4.2   65 31 0.17 400 130 2065 2.80 122 31 1.40 400 130 1959 2.43 131 25 2.83 400 127 1759 2.07 135 20 0.19 425 130 2338 3.09 123 37 1.27 425 129 2108 2.56 131 28 2.53 425 128 1664 1.95 135 17 0.21 450 132 2468 3.16 124 40 1.16 450 131 2212 2.61 134 30 2.38 450 130 1687 1.93 136 17 0.27 475 131 2438 3.10 126 39 1.20 475 131 2030 2.44 131 26 2.26 475 129 1472 1.68 135 13 The highest tenacity is achieved at 450° C. using the lowest tension applied.

Example 2

As-spun yarns were prepared as described in Example 1. The yarn was submitted to a two-step heat treatment procedure in which the first step was carried out at lower temperatures (300 to 360° C.) than the second step (450° C.), and lower than in Example 1, and wherein the tension applied on the yarns were higher in the first step than in the second step. Between the two steps the yarns were not reeled up, but transported by a godet that functions as a tension/speed control. Yarn tensions in the second step were between 0.25 and 0.29 cN/dtex. Residence time in both heating zones was 28 seconds.

The yarn properties and essential machine settings are given in Table 2.

TABLE 2 Tension Tension Linear Elongation oven 1 oven 2 oven 1 oven 2 density Tenacity at Break Modulus Toughness cN/dtex cN/dtex (° C.) (° C.) dtex [mN/tex] [wt %] [GPa] [J/g] as-spun yarn 153 1356 4.3  68 33 0.33 0.27 300 450 131 2603 3.3 124 43 1.63 0.26 300 450 131 2698 3.3 127 44 3.68 0.28 300 450 130 2770 3.3 129 46 0.24 0.29 330 450 130 2652 3.3 125 45 1.52 0.26 330 450 131 2698 3.3 128 45 3.40 0.25 330 450 131 2663 3.2 128 44 0.22 0.25 360 450 132 2601 3.4 122 45 1.44 0.26 360 450 132 2696 3.4 125 46 3.15 0.25 360 450 133 2656 3.3 126 44

Example 3

As-spun yarns were prepared as described in Example 1. The temperature of the spinneret assembly was 91° C., the neutralization fluid had a NaOH concentration of 0.8 wt % and the winding speed was 140 m/min. The as spun yarn had a linear density of 147 dtex, a tenacity of 1451 mN/tex, a modulus of 62 GPa and a toughness of 35 J/g. The yarn was submitted to a two-step heat treatment procedure in which the first step was carried out at lower temperatures (260 to 300° C.) than the second step (450° C.). The temperature of the first step was also lower than the temperature of the first step in Example 2. The tensions applied on the yarns were higher in the first step than in the second step. Between the two steps the yarns were not reeled up, but transported by a godet that functions as a tension/speed control. Yarn tensions in the second step were 0.1 cN/dtex. Residence time in both heating zones was 28 seconds.

The yarn properties and essential machine settings are given in Table 3.

TABLE 3 Tension Tension Linear Elongation oven 1 oven 2 oven 1 oven 2 density Tenacity at Break Modulus Toughness cN/dtex cN/dtex (° C.) (° C.) dtex [mN/tex] [wt %] [GPa] [J/g] 0.52 0.1 260 450 134 2730 3.67 114.8 50.0 1.93 0.1 135 2720 3.64 116.6 49.8 4.22 0.1 132 2790 3.62 118   50.5 0.46 0.1 280 450 133 2640 3.59 114.3 47.7 1.83 0.1 134 2710 3.58 117.4 49   4.03 0.1 134 2740 3.61 118.5 49.6 0.36 0.1 300 450 136 2660 3.61 116.5 48.6 1.79 0.1 136 2600 3.6  113.8 48   3.99 0.1 137 2780 3.63 118.4 50.3

Example 4

As-spun yarns were prepared according to Example 3, but the residence time in both heating zones was increased to 56 seconds.

The yarn properties and the most essential machine settings are given in Table 4.

TABLE 4 Tension Tension Linear Elongation oven 1 oven 1 oven 1 oven 2 Density Tenacity at Break Modulus Toughness cN/dtex cN/dtex (° C.) (° C.) dtex [mN/tex] [wt %] [GPa] [J/g] 0.42 0.1 300 450 135 2590 3.69 110.9 47.7 1.81 0.1 133 2720 3.66 114.9 49.6 4.06 0.1 132 2900 3.80 116.4 54.5

Example 5

As-spun yarn was prepared as described in Example 3, except that the winding speed was 160 m/min. The as spun properties of this yarn were: linear density 133 dtex, tenacity 1579 mN/tex, modulus 72 Gpa, and toughness 37 J/g.

This as-spun yarn had an S content of 1.84 wt %, a Cl content of 154 ppm, a Na content of 0.06 wt %, and a Ca content of 22 ppm.

This as-spun yarn was heat treated according to Example 4.

Tension in the first oven was 4.47 cN/dtex and in the second oven 0.13 cN/dtex.

This resulted in a yarn with a linear density 114 dtex, tenacity 2998 mN/tex, modulus 127 GPa, and toughness 51.5 J/g.

This heat treated yarn had an S content of 1.88 wt %, a Cl content of 100 ppm, a Na content of 0.07 wt %, and a Ca content of 37 ppm.

Example 6

A polymer obtained from a mixture of 40 mole % PPD and 10 mole % DABPI (and 50 mole % TDC) having η_(rel) 6.7 was dissolved in 99.8 wt % sulfuric acid as described in WO 2006/045517. Zone temperatures in the twin screw extruder were 85° C. The polymer concentration in the solution was 19 wt %, and the solution was spun through 100 spinning holes of 70 micron. The spinneret assembly was kept at 90° C. The flow was drawn in an airgap and coagulated in water of 2° C. After washing 0.8 wt % NaOH in water was used as neutralizing fluid, and in a second washing step the neutralizing fluid was washed off. The yarn was dried at 160° C. and reeled up at 160 m/min to obtain as-spun yarns, and heat treated as in Example 3.

The most essential machine settings and the yarn properties are given in Table 5.

TABLE 5 Tension Tension Linear Breaking Elongation Toughness oven 1 oven 1 oven 2 oven 2 density Tenacity at Break Modulus at Rupture cN/dtex ° C. cN/dtex ° C. dtex [mN/tex] [wt %] [GPa] [J/g] As-spun properties 220 1915 4.6  75    45   1.79 300 0.12 450 199 2310 2.47 137.3 28.6 3.69 300 0.11 450 195 2400 2.51 139.3 30.1 5.48 300 0.15 450 196 2360 2.46 139   28.8

Example 7

Yarns were spun according to Example 6 from polymers obtained from a mixture of 45 mole % PPD and 5 mole % DABPI (and 50 mole % TDC) having η_(rel) 5.7, giving a linear density of 213 dtex, a tenacity of 2140 mN/tex and a modulus of 80 GPa. The most important machine settings and yarn properties are given in Table 6.

TABLE 6 Tension Tension Linear Breaking Elongation Toughness oven 1 oven 1 oven 2 oven 2 density Tenacity at Break Modulus at Rupture cN/dtex ° C. cN/dtex ° C. dtex [mN/tex] [wt %] [GPa] [J/g] 1.84 300 0.12 450 196 1990 2.19 129.8 21.8 2.64 300 0.12 450 194 2000 2.17 131.6 22   3.84 300 0.11 450 195 1950 2.11 132.0 20.4 5.18 300 0.10 450 193 2120 2.22 135   23.2

Example 8

A polymer obtained from a mixture of 35 mole % PPD and 15 mole % DABPI (and 50 mole % TDC) having η_(rel) 6.4 was dissolved in 99.8 wt % sulfuric acid as described in WO 2006/045517. Zone temperatures in the twin screw extruder were 85° C. The polymer concentration in the solution was 20 wt % and the solution was spun through 106 spinning holes of 75 micron. The spinneret assembly was kept at 85° C. The flow was drawn in an airgap and coagulated in water of 2.5° C. After washing 0.8 wt % NaOH in water was used as neutralizing fluid, and in a second washing step the neutralizing fluid was washed off. The yarn was dried at 160° C. and reeled up at 160 m/min to obtain as-spun yarns, and heat treated as in Example 3. Before heat treatment the as-spun yarn was pre-dried during 24 hours at 50° C.

The most essential machine settings and the yarn properties are given in Table 7.

TABLE 7 Tension Tension Linear Breaking Elongation Toughness oven 1 oven 1 oven 2 oven 2 density Tenacity at Break Modulus at Rupture cN/dtex ° C. cN/dtex ° C. dtex [mN/tex] [wt %] [GPa] [J/g] As-spun properties 190 1606 4.35  67.7 37.5 0.92 300 0.088 450 169 2590 3.01 131.1 39.1 1.79 300 0.082 450 170 2640 3.03 131   39.8 2.74 300 0.065 450 170 2720 3.04 134   41.2 

1. A multifilament aramid yarn having a tenacity of at least 2500 mN/tex wherein the yarn is made of a copolymer obtained from a mixture of monomers comprising DAPBI, an aromatic para-diamine, and an aromatic para-diacid, at least 12.5 mole % of the monomers is DAPBI, less than 20 mole % of the monomers is Cl-PPD, and the yarn has a sulfur content of at least 0.1 wt %.
 2. The multifilament aramid yarn of claim 1, wherein the aromatic para-diamine is exclusively PPD. 